Wacker Neuson 803 User manual

Operator's Manual

Track Excavator

803

803 dual power

Machine type E08-01

Edition 3.6

Order no 1000287384

Language us

1000287384

This Operator's Manual includes

the AEM 3afety -anual #%

Dokument ationen

Documentations Order no

Operator's Manual 1000287384

Service Manual 1000164843

Spare parts list 1000161641

Printed in Michigan, USA

No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical

including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from the

manufacturer.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.

Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution.

Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we

may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which

have already been delivered and which will not be implemented on these machines.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted. Non-metric

weights and measurements are approximate.

The cover features machines with possible optional equipment.

Pictures and graphics are symbolic representations and can differ from the actual product.

Wacker Neuson Linz GmbH

Flughafenstraße 7

A-4063 Hörsching

Legend

Original Operator‘s Manual x

Translation of original Operator‘s

Manual

–

Edition 3.6

Date 03/2015

Document OM 803 us

OM 803 us - Ausgabe 3.6 * Ba803us3_6IVZ.fm 1-1

Table of contents

Introduction 1

Information on this Operator’s Manual ..................................................................... 1-1

Machine overview (up to serial no. AI00966) ........................................................... 1-2

Machine overview (from serial no. AI00967) ........................................................... 1-3

Brief description ....................................................................................................... 1-4

Traveling drive ................................................................................................... 1-4

Operating hydraulics .......................................................................................... 1-4

Cooling system .................................................................................................. 1-4

Definition of the term “Protective Structure” ...................................................... 1-5

Explanation of abbreviations ............................................................................. 1-5

Rollbar ..................................................................................................................... 1-5

Mechanical integrity ................................................................................................. 1-5

Responsibility for machine equipped with protective structures ........................ 1-5

Fields of application, attachments ........................................................................... 1-6

Regulations .............................................................................................................. 1-7

TOPS rollbar (up to serial no. AI00966)/ROPS ....................................................... 1-7

EC Declaration of Conformity .................................................................................. 1-8

Type labels and component numbers ...................................................................... 1-9

Overview of adhesive labels .................................................................................. 1-10

Overview of safety labels ....................................................................................... 1-15

Safety instructions 2

Safety Symbols Found In This Manual .................................................................... 2-1

Warranty .................................................................................................................. 2-2

Disposal ................................................................................................................... 2-2

Designated Use ....................................................................................................... 2-2

Preparing To Use The Machine ............................................................................... 2-3

Conditions for use .............................................................................................. 2-3

User training and knowledge ............................................................................. 2-3

Preparing for use ............................................................................................... 2-3

Information on visibility ...................................................................................... 2-4

Modifications and spare parts ............................................................................ 2-4

Operator and Technician Qualifications and Basic Responsibilities ........................ 2-4

User/Owner responsibility .................................................................................. 2-4

Repair person qualifications .............................................................................. 2-4

Safety Instructions Regarding Operation ................................................................. 2-5

Preparing for use ............................................................................................... 2-5

Starting and stopping ......................................................................................... 2-5

Work area awareness ........................................................................................ 2-6

Danger zone awareness .................................................................................... 2-6

Operating the machine ...................................................................................... 2-6

Carrying passengers ......................................................................................... 2-6

Mechanical integrity ........................................................................................... 2-7

Traveling ............................................................................................................ 2-7

Operator Protection System .................................................................................... 2-8

TOPS rollbar (up to serial no. AF01416) ........................................................... 2-8

ROPS rollbar ..................................................................................................... 2-8

Traveling without TOPS rollbar (up to serial no. AF01416) ............................... 2-8

Traveling without ROPS rollbar ......................................................................... 2-8

Shatter protection (Option) ................................................................................ 2-9

Work range and restricted visibility .................................................................... 2-9

Applications with Lifting Gear ................................................................................ 2-10

General information ......................................................................................... 2-10

Operation with lowered TOPS rollbar (up to serial no. AI00966) ..................... 2-10

Table of contents

1-2 OM 803 us - Ausgabe 3.6 * * Ba803us3_6IVZ.fm

Table of contents

Operation with lowered ROPS rollbar .............................................................. 2-10

Attachments ........................................................................................................... 2-10

General information regarding attachments .................................................... 2-10

Installation notes .............................................................................................. 2-11

Trailers ................................................................................................................... 2-11

Hammer operation ................................................................................................. 2-12

Safety instructions ........................................................................................... 2-12

Working with a hammer ................................................................................... 2-12

Transport and Towing ............................................................................................ 2-13

Towing ............................................................................................................. 2-13

Transporting ..................................................................................................... 2-13

Safety Guidelines for Maintenance ........................................................................ 2-13

General maintenance notes ............................................................................. 2-13

Personal safety measures ............................................................................... 2-14

Preparing for maintenance and repair work ..................................................... 2-14

Performing maintenance and repairs ............................................................... 2-15

Special Hazards ..................................................................................................... 2-15

Electrical energy .............................................................................................. 2-15

Underground electric lines ............................................................................... 2-16

Overhead electric lines .................................................................................... 2-16

Gas, dust, steam, smoke ................................................................................. 2-17

Hydraulics ........................................................................................................ 2-17

Noise ................................................................................................................ 2-17

MSDS .............................................................................................................. 2-17

Tracks .............................................................................................................. 2-17

Battery ............................................................................................................. 2-18

Safety Guidelines while using Internal Combustion Engines ................................. 2-18

Running the engine .......................................................................................... 2-18

Fueling the engine ........................................................................................... 2-18

Dual Power option ........................................................................................... 2-19

Operation 3

Control stand overview (up to serial no. AI00814) ................................................... 3-2

Control stand overview (from serial no. AI00815) .................................................... 3-5

Display elements (overview) .................................................................................... 3-6

Putting into operation ............................................................................................... 3-7

Safety instructions ............................................................................................. 3-7

Putting into operation for the first time ............................................................... 3-7

Running-in period .............................................................................................. 3-7

Check lists ......................................................................................................... 3-8

Start-up checklist ............................................................................................... 3-8

Operation checklist ............................................................................................ 3-9

“Parking” checklist ............................................................................................. 3-9

Driving the excavator ............................................................................................. 3-10

Starter .............................................................................................................. 3-10

Throttle ............................................................................................................. 3-10

Traveling signal (option) .................................................................................. 3-11

Indicator lights and warning lights (overview) .................................................. 3-11

Starting the engine: general ............................................................................. 3-13

Procedure ........................................................................................................ 3-13

Starting at low temperatures .................................................................................. 3-14

When the engine has started ........................................................................... 3-14

Engine and machine warm-up ......................................................................... 3-14

Jump-starting the engine (supply battery) ....................................................... 3-15

Special instructions for driving on public roads ................................................ 3-16

Travel position ................................................................................................. 3-16

Starting machine travel .................................................................................... 3-16

OM 803 us - Ausgabe 3.6 * Ba803us3_6IVZ.fm 1-3

Table of contents

Operating temperature range .......................................................................... 3-16

Travel levers .................................................................................................... 3-16

ISO/SAE changeover (option) ......................................................................... 3-17

Hydraulic brake ................................................................................................ 3-18

Stabilizer blade as a parking brake ................................................................. 3-18

Machine travel on slopes ....................................................................................... 3-19

Stabilizer blade operation ................................................................................ 3-22

Changing the width of the stabilizer blade ....................................................... 3-22

Telescopic travel gear ..................................................................................... 3-24

Upper carriage lock ......................................................................................... 3-25

Parking the machine ........................................................................................ 3-26

Parking the machine on slopes ....................................................................... 3-26

Light system .................................................................................................... 3-27

Power outlet ..................................................................................................... 3-27

Seat adjustment ............................................................................................... 3-28

Access to the control stand .................................................................................... 3-28

Telescopically extended travel gear ................................................................ 3-29

Lowerable TOPS rollbar (up to serial no. AI00966) (option) .................................. 3-30

Lowering the rollbar ......................................................................................... 3-30

Raising the rollbar ............................................................................................ 3-31

Lowerable ROPS rollbar (up to serial no. AI00966) (option) ................................. 3-32

Lowering the rollbar ......................................................................................... 3-32

Raising the rollbar ............................................................................................ 3-33

Lowering the rollbar ......................................................................................... 3-33

Raising the rollbar ............................................................................................ 3-33

Lowerable ROPS rollbar (from serial no. AI00967) (option) .................................. 3-34

Lowering the rollbar ......................................................................................... 3-34

Raising the rollbar ............................................................................................ 3-35

Seat belt (option) ............................................................................................. 3-37

Engine cover .................................................................................................... 3-41

Towing the machine ........................................................................................ 3-43

Lifting the machine .......................................................................................... 3-44

Loading and transporting the machine ............................................................ 3-46

Tying down the machine .................................................................................. 3-47

Shatter protection (option) (from serial no. AI00967) ............................................. 3-48

Working with the machine ...................................................................................... 3-50

General safety instructions .............................................................................. 3-50

Control lever overview ........................................................................................... 3-52

Left-hand control lever ..................................................................................... 3-52

Right-hand control lever .................................................................................. 3-52

Boom swivel controls ............................................................................................. 3-53

Boom swivel controls (up to serial no. AI00975) ............................................. 3-53

Boom swivel controls (from serial no. AI00976) .............................................. 3-54

Auxiliary hydraulics ................................................................................................ 3-55

Auxiliary hydraulics (up to serial no. AI00975) ................................................ 3-55

Auxiliary hydraulics (from serial no. AI00976) ................................................. 3-56

Auxiliary hydraulics (double-action option) (up to serial no. AI00975) ............. 3-57

Auxiliary hydraulics (double-action option) (from serial no. AI00976) ............. 3-58

Emergency lowering ........................................................................................ 3-60

Rotating the upper carriage ............................................................................. 3-61

Upper carriage deceleration ............................................................................ 3-61

Lock lever .............................................................................................................. 3-62

Lock lever (up to serial no. AI00814) ............................................................... 3-62

Lock lever (from serial no. AI00815) ................................................................ 3-62

Dual Power (option) ............................................................................................... 3-63

Overview of connections ................................................................................. 3-64

Coupling .......................................................................................................... 3-65

1-4 OM 803 us - Ausgabe 3.6 * * Ba803us3_6IVZ.fm

Table of contents

Checking the hydraulic oil levels of the power unit and excavator .................. 3-67

Changeover from HPU to diesel operation ...................................................... 3-68

Changeover from diesel to HPU operation ...................................................... 3-69

Uncoupling ....................................................................................................... 3-70

Charging the excavator battery ........................................................................ 3-71

Charging the battery with the power unit ......................................................... 3-73

Charging the battery with the mains ................................................................ 3-73

Dual-Power operation with rotating beacon ..................................................... 3-74

Pressure release on the auxiliary hydraulics ......................................................... 3-75

Releasing pressure .......................................................................................... 3-75

Re-equipping attachments ..................................................................................... 3-75

Specific safety instructions .............................................................................. 3-76

Removing a bucket .......................................................................................... 3-76

Installing a bucket ............................................................................................ 3-77

Connections for auxiliary hydraulics ................................................................ 3-77

Connections for auxiliary hydraulics (stick hose routing option) ...................... 3-78

Attachments ..................................................................................................... 3-79

Maintenance of attachments ............................................................................ 3-79

Working with the standard bucket .................................................................... 3-79

Inadmissible work procedures ......................................................................... 3-79

Excavator work position ................................................................................... 3-80

Bucket position when digging .......................................................................... 3-81

Excavating trenches ........................................................................................ 3-81

Loading ............................................................................................................ 3-81

Grading ............................................................................................................ 3-82

Excavating trenches sideways ......................................................................... 3-82

Grading .................................................................................................................. 3-83

Grading ............................................................................................................ 3-83

Working alongside trenches ............................................................................ 3-84

Stabilizer blade at rear ..................................................................................... 3-84

Malfunctions 4

Engine trouble .......................................................................................................... 4-1

Maintenance 5

Introduction .............................................................................................................. 5-1

Fuel system .............................................................................................................. 5-2

Specific safety instructions ................................................................................ 5-2

Refueling ............................................................................................................ 5-3

Draining fuel ....................................................................................................... 5-3

Stationary fuel pumps ........................................................................................ 5-3

Bleeding the fuel system .................................................................................... 5-4

Fuel prefilter with water separator ..................................................................... 5-5

Engine lubrication system ........................................................................................ 5-6

Checking the oil level ......................................................................................... 5-7

Adding engine oil ............................................................................................... 5-7

Engine cooling system ............................................................................................. 5-8

Specific safety instructions ................................................................................ 5-8

Checking the coolant level/adding coolant ...................................................... 5-10

Cleaning the radiator ....................................................................................... 5-11

Air filter ................................................................................................................... 5-12

Air filter (up to serial no. AI00875) ................................................................... 5-13

Replacing air filter elements ............................................................................ 5-13

Air filter (from serial no. AI00876) .................................................................... 5-14

Replacing air filter elements ............................................................................ 5-14

V-belt ...................................................................................................................... 5-15

Checking V-belt tension ................................................................................... 5-15

OM 803 us - Ausgabe 3.6 * Ba803us3_6IVZ.fm 1-5

Table of contents

Retightening the V-belt .................................................................................... 5-15

Hydraulic system ................................................................................................... 5-16

Important information on the hydraulic system ................................................ 5-16

Checking the hydraulic oil level ....................................................................... 5-17

Adding hydraulic oil ......................................................................................... 5-17

Important information on the use of biodegradable oil .................................... 5-18

Checking hydraulic pressure lines ................................................................... 5-19

Overview of lubrication points ................................................................................ 5-20

Parking the machine ........................................................................................ 5-21

Swiveling cylinder lubrication points ................................................................ 5-21

Lubricating the ball bearing race of the live ring .............................................. 5-22

Lubricating the teeth of the live ring ................................................................. 5-23

Ball sockets (ISO/SAE changeover option) ..................................................... 5-24

Tracks .................................................................................................................... 5-25

Checking track tension .................................................................................... 5-25

Tightening the tracks ....................................................................................... 5-26

Traveling drive ....................................................................................................... 5-27

Electrical system .................................................................................................... 5-28

Specific safety instructions .............................................................................. 5-28

Servicing and maintenance at regular intervals ............................................... 5-28

Instructions concerning specific components .................................................. 5-29

Alternator ......................................................................................................... 5-29

Battery ............................................................................................................. 5-30

General maintenance ............................................................................................ 5-31

Cleaning .......................................................................................................... 5-31

General instructions for all areas of the machine ............................................ 5-31

Control stand ................................................................................................... 5-32

Exterior of the machine .................................................................................... 5-32

Engine compartment ....................................................................................... 5-32

Threaded fittings and attachments .................................................................. 5-33

Pivots and hinges ............................................................................................ 5-33

Preparatory work before taking out of service ....................................................... 5-33

Maintenance if the machine is out of service for a longer period of time ............... 5-34

Putting into operation again ............................................................................. 5-34

Fluids and lubricants .............................................................................................. 5-35

Oil change and filter replacement (hydraulics) ................................................ 5-37

Maintenance plan (overview) ................................................................................. 5-38

Maintenance label .................................................................................................. 5-43

Explanation of symbols on the maintenance label .......................................... 5-43

Technical data 6

Chassis .................................................................................................................... 6-1

Engine ...................................................................................................................... 6-1

Travel gear and swivel unit ...................................................................................... 6-2

Stabilizer blade ........................................................................................................ 6-3

Operating hydraulics ................................................................................................ 6-3

Connection values of Dual Power option ................................................................. 6-3

Electrical system ...................................................................................................... 6-3

Fuses behind the right-hand trim ....................................................................... 6-4

Relays behind the right-hand trim ...................................................................... 6-4

1-6 OM 803 us - Ausgabe 3.6 * * Ba803us3_6IVZ.fm

Table of contents

Fuses and relays with Dual Power option .......................................................... 6-5

Noise levels .............................................................................................................. 6-6

Vibration ................................................................................................................... 6-6

Coolant compound table .......................................................................................... 6-9

Weight ...................................................................................................................... 6-9

Dimensions model 803 (up to serial no. AI00966) ................................................. 6-10

Dimensions model 803 with rollbar (from serial no. AI00967) ............................... 6-11

Dimensions model 803 without rollbar (from serial no. AI00967) .......................... 6-12

Lift capacity tables 803 .......................................................................................... 6-13

Safety instructions – lift capacity table ............................................................. 6-13

OM 803 us - Ausgabe 3.6 * Ba803us3_6SIX.fm 1-1

Index

A

Abbreviations .........................................................................................1-1

Air filter

.................................................................................................5-12

B

Biodegradable oil .................................................................................5-18

C

Changeover from diesel to HPU operation ..........................................3-69

Changeover from HPU to diesel operation

..........................................3-68

Check lists .............................................................................................3-8

Cleaning the radiator ...........................................................................5-11

D

Designated use and exemption from liability .........................................2-2

Display elements (overview) ..................................................................3-6

Driving on public roads ........................................................................3-16

Driving the excavator

...........................................................................3-10

E

Entry and exit .......................................................................................3-28

G

Gradient angle .....................................................................................3-20

I

Important information

On the Operator’s Manual ..............................................................1-1

Indicator lights and warning lights ........................................................3-11

Instrument panel overview

.....................................................................3-6

ISO/SAE changeover ...........................................................................3-17

L

Lateral angle of inclination ...................................................................3-21

Legal regulations

...................................................................................1-7

Lifting the machine ...............................................................................3-44

Light system .........................................................................................3-27

Lock lever

............................................................................................3-62

Lubricating the ball bearing race of the live ring ..................................5-22

Lubricating the teeth of the live ring .....................................................5-23

M

Machine

Brief description

.............................................................................. 1-4

Fields of application ........................................................................ 1-6

Loading and transporting .............................................................. 3-46

Overview

........................................................................................ 1-2

Maintenance

Adding coolant .............................................................................. 5-10

Adding engine oil

............................................................................ 5-7

Adding hydraulic oil ...................................................................... 5-17

Air filter ................................................................................5-13, 5-14

Biodegradable oil

.......................................................................... 5-18

Bleeding the fuel system ................................................................ 5-4

Checking the coolant level ........................................................... 5-10

Checking the engine oil level

.......................................................... 5-7

Checking the hydraulic oil level .................................................... 5-17

Cleaning ....................................................................................... 5-31

Electrical system

.......................................................................... 5-28

Engine and hydraulics cooling system ........................................... 5-8

Engine lubrication system .............................................................. 5-6

Fuel system

.................................................................................... 5-2

General maintenance ................................................................... 5-31

Hydraulic pressure lines ............................................................... 5-19

Hydraulic system

.......................................................................... 5-16

Instructions concerning specific components ............................... 5-29

Maintenance plan ......................................................................... 5-38

Pivots and hinges

......................................................................... 5-33

Servicing and maintenance at regular intervals ........................... 5-28

Threaded fittings ........................................................................... 5-33

Track maintenance

....................................................................... 5-25

V-belt ............................................................................................ 5-15

Maintenance if the machine is out of service for a longer period of time ...

5-34

N

Noise levels ......................................................................................... 1-11

O

Operation .............................................................................................. 3-1

Before starting the engine

............................................................ 3-13

Control stand overview ............................................................3-2, 3-5

Parking the machine ..................................................................... 3-26

Seat belt height adjustment

.................................................3-38, 3-40

Starting machine travel ................................................................. 3-16

Starting the engine

....................................................................... 3-13

Operation with lowered ROPS rollbar ................................................. 2-10

Operation with lowered TOPS rollbar (up to serial no. AI00966) ........ 2-10

P

Preparing for maintenance and repair work ........................................ 2-14

Putting into operation .....................................................................3-2, 3-5

Check lists ...................................................................................... 3-8

Putting into operation for the first time

............................................ 3-7

Safety instructions .......................................................................... 3-7

R

Refueling ............................................................................................... 5-3

Running-in period

.................................................................................. 3-7

Index

I

1-2 OM 803 us - Ausgabe 3.6 * * Ba803us3_6SIX.fm

Index

S

Safety instructions .................................................................................2-1

General conduct

.............................................................................2-3

Identification ....................................................................................2-1

Seat belt ..............................................................................................3-37

Seat belt height adjustment

....................................................... 3-38, 3-40

Shatter protection ........................................................................ 2-9, 3-48

Starting aid ..........................................................................................3-15

T

Technical data .......................................................................................6-1

Chassis ...........................................................................................6-1

Coolant compound table .................................................................6-9

Dimensions

................................................................6-10, 6-11, 6-12

Electrical system .............................................................................6-3

Engine .............................................................................................6-1

Noise levels

....................................................................................6-6

Operating hydraulics .......................................................................6-3

Vibration ..........................................................................................6-6

Track maintenance

..............................................................................5-25

W

Warranty ................................................................................................2-2

Working

Freeing the machine

.....................................................................3-82

Recommendations ........................................................................3-82

OM 803 us – Edition 3.6 * 803b110.fm 1-1

Introduction

1 Introduction

1.1 Information on this Operator’s Manual

The Operator’s Manual is stored in the storage bin at the rear of the seat.

This Operator’s Manual contains important information on how to work safely, correctly

and economically with the machine. Therefore, it aims not only at new personnel, but it

also serves as a reference for experienced personnel. It helps to avoid hazardous situa-

tions and reduce repair costs and downtimes. Furthermore, the reliability and the service

life of the machine will be increased by following the instructions in the Operator’s Manual.

This is why the Operator’s Manual must always be kept at hand in the machine.

Your own safety, as well as the safety of others, depends to a great extent on how the

machine is moved and operated. Carefully read the Operator’s Manual before putting the

machine into operation. This Operator’s Manual will help to familiarize yourself more easily

with the machine, thereby enabling you to use it more safely and efficiently.

Follow chapter “Safety Instructions” in particular. As a rule, keep the following in mind:

Careful and prudent working is the best way to avoid accidents!

Operational safety and readiness of the machine do not only depend on your skill, but also

on maintenance and servicing of the machine. This is why regular maintenance and ser-

vice work is absolutely necessary.

Extensive maintenance and repair work must always be performed by a Wacker Neuson

service center. Use only original spare parts for repairs. This ensures operational safety

and readiness of your machine, and maintains its value.

• Special equipment and superstructures are not described in this Operator’s Manual.

• We reserve the right to improve the technical standard of our machines without

adapting the Operator’s Manual.

• Modifying Wacker Neuson products and fitting them with additional equipment and

attachments not included in our delivery program requires Wacker Neuson’s written

authorization, otherwise warranty and product liability for possible damage caused by

these modifications shall not be applicable.

• Subject to modifications and printing errors.

Your Wacker Neuson dealer will be pleased to answer any further questions regarding the

machine or the Operator’s Manual.

Abbreviations/symbols

• Identifies a list

• Subdivision within lists or an activity. Follow the steps in the recommended order

☞Identifies an activity

➥Description of the effects or results of an activity

This symbol shows the travel direction – for better orientation in figures and graphics.

1-2 OM 803 us – Edition 3.6 * * 803b110.fm

Introduction

1.2 Machine overview (up to serial no. AI00966)

Fig. 1: Machine outside views

1 Boom light

2 Boom

3Stick

4Track

5 Travel gear

6 Stabilizer blade

7 Handhold

8 Lifting eye for loading/tying down the machine

9 Engine cover

10 Storage bin for Operator’s Manual

11 Lock lever

7

5

7

3

2

1

4

8

10

2

6

8

9

3

11

546

8

OM 803 us – Edition 3.6 * 803b110.fm 1-3

Introduction

1.3 Machine overview (from serial no. AI00967)

Fig. 2: Machine outside views

1 Boom light

2 Boom

3Stick

4Track

5 Travel gear

6 Stabilizer blade

7 Handhold

8 Lifting eye for loading/tying down the machine

9 Engine cover

10 Storage bin for Operator’s Manual

11 Lock lever

12 ROPS rollbar (option)

13 Shatter protection (option)

5

3

1

4

8

2

6

8

9

2

10

3

11

546

8

12

7

11

7

13

1-4 OM 803 us – Edition 3.6 * * 803b110.fm

Introduction

1.4 Brief description

The model 803 excavator is a self-propelled work machine.

Get informed on and follow the legal regulations of your country.

This machine is a versatile and powerful helper for moving earth, gravel and debris on con-

struction sites and elsewhere. A wide range of attachments accounts for the numerous

applications of the machine, including hammer operation.

See chapter Fields of application, attachments for further applications.

The main components of the machine are:

• Undercarriage

• Tracked travel gear

• Stabilizer blade

• Live ring

• Upper carriage

• Water-cooled diesel engine

• Hydraulic and electrical components

• Boom

Information!

The machine can be equipped with the “Telematic” option (for transmitting

operating data, location, etc. via satellite)!

Traveling drive

The diesel engine permanently drives two gear pumps the oil flow of which is sent to the

hydraulic motor currently actuated.

Operating hydraulics

The diesel engine permanently drives two gear pumps the oil flow of which is sent to the

operating hydraulics as required. The oil flow of these pumps depends on the diesel

engine speed.

Cooling system

An indicator light on the instrument panel of the machine ensures constant monitoring of

the engine oil and coolant temperature.

OM 803 us – Edition 3.6 * 803b110.fm 1-5

Introduction

Definition of the term “Protective Structure”

Protective structures are additional elements that protect the operator or user against haz-

ards. These elements can be installed later on or as standard equipment.

Explanation of abbreviations

ROPS:

Roll Over Protective Structure

TOPS:

Tip Over Protective Structure

1.5 Rollbar

The rollbar has been specially designed for protection in case of an accident.

• ROPS/TOPS tested rollbar (option).

• Shatter protection (option from AI00967); protective structure against fragments flying

around from the front.

1.6 Mechanical integrity

DANGER

Accident hazard due to modified cabin and protective structures!

Incorrect work on the cabin and protective structures causes serious injury or death.

• No drilling, cutting or grinding on protective structures.

• Welding, straightening or bending work on protective structures is prohibited.

• Have damaged protective structures immediately replaced.

Information!

Check the rollbar and all protective structures once a day for damage.

Information!

Protective structures may only be installed or removed by a Wacker Neuson

service center.

Responsibility for machine equipped with protective structures

The decision regarding the necessary protective structures (type and level I or II) must be

made by the machine owner and depends on the specific work situation.

The machine owner must observe the national regulations and he must inform the opera-

tor on the protective structure to be used in a specific work situation.

1-6 OM 803 us – Edition 3.6 * * 803b110.fm

Introduction

1.7 Fields of application, attachments

The attachments will decide in the first place how the excavator is used.

NOTICE

In order to avoid damage to the machine, only the attachments listed below

have been certified.

• Please contact your Wacker Neuson dealer if you wish to use other attachments.

Using tools of other manufacturers, or tools which have been released for other excavator

types, can reduce the machine’s output and stability considerably, and can also cause

damage to the machine and injury to the operator or personnel.

Always compare the weight of the attachment and its maximum payload with the indica-

tions in the lift capacity table. Never exceed the maximum payload stated in the lift capac-

ity table.

Information!

Please refer to the Operator’s and maintenance manual of the attachment

manufacturer for using and performing maintenance on attachments such as

hammers, etc.

Use: attachment

Description of attachment Weight Capacity Remarks

Backhoe bucket B = 250 mm (10 in)

(standard bucket)

15 kg

(33 lbs)

0.014 m

3

(0.50 ft

3

)

Backhoe bucket B = 370 mm

(14.5 in)

17 kg

(38 lbs)

0.018 m

3

(0.63 ft

3

)

Backhoe bucket B = 370 mm

(14.5 in)

19 kg

(42 lbs)

0.024 m

3

(0.85 ft

3

)

Bucket B = 700 mm (27.5 in)

24.5 kg

(54 lbs)

0.027 m

3

(0.95 ft

3

)

Hydraulic hammer NE06

63 kg

(139 lbs)

--

OM 803 us – Edition 3.6 * 803b110.fm 1-7

Introduction

1.8 Regulations

Requirements to be met by the operator

Earth moving machines may be driven and serviced only by persons who meet the follow-

ing requirements:

• 18 years or older

• Physically and mentally suited for this work

• Persons have been instructed in driving and servicing the earth moving machine and

have proven their qualifications to the contractor

• Persons are expected to perform work reliably.

They have been appointed by the contractor for driving and servicing the earth moving

machine.

Get informed on and follow the legal regulations of your country.

1.9 TOPS rollbar (up to serial no. AI00966)/ROPS

NOTICE

Always fasten the seat belt if the rollbar is raised.

NOTICE

Do not use the seat belt if the rollbar is lowered, or if the machine is not

equipped with a rollbar.

• Machine operation with the rollbar lowered is prohibited – see chapter

Operation with lowered ROPS rollbar on page 2-9.

1-8 OM 803 us – Edition 3.6 * * 803b110.fm

Introduction

1.10 EC Declaration of Conformity

The indications specified above correspond to the existing information at time of going to press. They have possibly changed in the mean-

time (refer to the original declaration of conformity supplied with the machine). Applies to EU countries, and countries with legislation sim-

ilar to that of the EU. Applies to all machines with CE marks that have not been modified without authorization since the product was

placed on the market.

Manufacturer

Wacker Neuson Linz GmbH, Flughafenstr. 7, 4063 Hörsching, Austria

Product

Declaration of conformity

Notified body according to Directive 2006/42/EC, appendix XI:

DGUV Test-, Prüf- und Zertifizierungsstelle

Fachausschuss Bauwesen, Landsberger Str. 309, 80687 Munich, Germany

Distinguishing EU number 0515

Notified body involved in procedure

TÜV SÜD Industrie Service GmbH

Westendstr. 199

D-80686 Munich

Directives and standards

We hereby declare that this product corresponds to the relevant regulations of the following Directives and standards:

2006/42/EC, 2005/88/EC, 2000/14/EC;

DIN EN ISO 12100-1, DIN EN ISO 12100-2, DIN EN 474-1 and DIN EN 474-5 (except item C.3.3),

DIN EN ISO 3471, EN ISO 3744, DIN EN ISO 3449

Authorized representative for the compilation of technical documentation

Thomas Köck, team leader technical documentation

Flughafenstr. 7

4063 Hörsching/Austria

Austria

Machine designation Hydraulic excavator

Model/version E08-01

Trade name 803

Serial number --

Output in kW 9.6

Measured sound power level dB(A) 92.6

Guaranteed sound power level dB(A) 93

Johannes Mahringer,

Managing director

EC Declaration of Conformity

OM 803 us – Edition 3.6 * 803b110.fm 1-9

Introduction

1.11 Type labels and component numbers

Information!

Type, quantity and position of the labels depend on options, country and machine.

Serial number

The serial number is stamped on the machine chassis. It is also located

on the type label.

The type label is located at the front right on the machine chassis (at control stand level).

Type label information (example):

Machine designation: HYDRAULIC EXCAVATOR

Model: ---------------

Model year: ---------------

CEE no.: ---------------

Output: ---------------

Serial no.: ---------------

Max. payload: ---------------

GWR: ---------------

Operating weight: ---------------

Front GAWR: ---------------

Transport weight: ---------------

Rear GAWR: ---------------

Version: ---------------

Other information – see chapter 6 Technical data on page 6-1

ROPS bar type label

The type label is located at the front right, on one side of the rollbar.

Engine number

The type label is located on the cylinder-head cover (engine).

Fig. 1: Type label: location (symbolic representation)

Fig. 1: Type label (symbolic representation)

Fig. 2: ROPS bar type label (symbolic representation)

Fig. 3: Diesel engine number (symbolic representation)

1-10 OM 803 us – Edition 3.6 * * 803b110.fm

Introduction

1.12 Overview of adhesive labels

1

1. Number and position of adhesive labels can differ depending on country.

1000259981

ULTRA LOW SULFUR

FUEL ONLY

370-1818

DIESEL

D

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Wacker Neuson 803 User manual

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